Composite construction material and method of making the same



Oct. 29, 1935. P, B, BR|LL Er AL 2,018,911

COMPOSITE CONSTRUCTION MATERIAL AND METHOD yOF MAKING THE SAME FiledJune 29, 1934 2 sheets-sheet 1 Inventor-5; Philip'rw Gute H` 1/1s Oct.29, 1935. P. B, BRILL Er AL 2,018,911

COMPOSITE CONSTRUCTION MATERIAL AND METHOD OF MAKING' THE SAME*- 2Sheets-Sheet 2 Filed June 29, 1954 l .in f 4 r @fr ,l

Inventors PJ/ i 686W@ His/115 @ll w Patented Oct. 29, 1935 COMPOSITECONSTRUCTION MATERIAL AND METHOD OF MAKING THE SAIWE Philip B. Brill,New Haven, Conn., and George H. Ellis, St. Paul, Minn., assignors to TheInsulite Company, Minneapolis, Minn., a-cor .poration of MinnesotaApplication June 29, 1934, Serial No. 733,078

11 Claims.

This invention relates ,to partition or panel structures which are madeup of a plurality of sections Whose meeting edges are adapted to beconcealed by pilasters. The sections and the pilasters being sointerlocked as to permit the same to be not only readily assembled by toalso permit them to be disassembled.

One object of the present invention is to pro vide a sectional partitionwherein the same elements could serve to lock the pilasters to themeeting. edges of the two sections, also serve the purpose of lockingsaid two sections together.

Another object of the invention is to provide a partition post which maybe used between partition pieces to effectively hold the same togetherand to reduce the length of time necessary in the erection of partitionsin rooms having ceilings of various heights.

Another object of the invention is to` produce a heat insulatingstructural material from a core of woody fibers and particularly acomposition core with heat insulating qualities and a surface layer orlayers of material, `preferably sheet steel. The layers of metal beingsecured in place by a cementitious material that will cause a thoroughland secure adhesion and a substantially inseparable union between -thecomposition board and the metal over all the parts of the cementedsurface to be procured.

In the preferred construction of the heat insulating structural materialthere is employed a core of "Insulite" which has been treated with afireprooiing material and an insecticide and fungi resisting material,and a surface layer or layers of steel which are cemented to said coreby the use of a casein adhesive.

A composition material formed in accordance with this invention willpossess heat insulating properties of a high degree, the core of whichwill be permanent in character and will not disintegrate under vibrationand the composite. structure will possess great structural strength,lightness in weight, durability, hardness of surface, and fungi andtermite resisting qualities. Such material may be used in the buildingup of panels for use in the walls of state rooms on boats and for thewalls of refrigerator railway cars, refrigerator plants, refrigeratorshipping boxes, and other similar refrigerating structures designed toprevent the transmission of heat to or from goods transported and storedtherein and for many other uses.

To enable others skilled in the art to fully comprehend the underlyingfeatures of the invention that they may embody the same in various (Cl.l2-68) modifications and structure and relationship contemplateddrawings depicting preferred forms have been annexed as a part of thisdisclosure and in such drawings, similar reference characters denotecorresponding parts throughout all the views of which,

Fig. 1 is a disassembled view of one form of the pilaster and the metalclad insulating material.

Fig. 2 is an assembled view of a modified form.

Fig. 3 is a perspective view of a part of one of 10 the pilasters; and

Fig. 4 is a modified form of the construction shown in Fig. 1.

Fig. 5 is a disassembled view of another form of a pilaster andthe metalclad insulating material.

Fig. 6 is an assembled view of the same.

Fig. '7 is a view of a sheet of metal clad insulating material showingmodified form having' a Wedge in the kerf.

Figure 8 is a view of a composite panel having a 20 modified form ofwedge in the kerf; and

Fig. 9 is a view of the wedge disclosed in Fig. 1.

When forming the core sheet from wood or woody fibers there isincorporated in the pulp before the sheet is formed termite, fungi andiire resisting materials. If desired water proofing material also may beadded so that the nal product will be highly resistant to the absorptionof moisture. Of course, it is to be understood that the water proofingand re proofing materials may be added after the sheet is formed.

Referring to Fig. 1 the core sheets are indicated at I0. After the coresheets l0 have been formed they are coated with a suitable adhesive,preferably a casein adhesive, and then the surface plates Il, of thinmetal are applied to the core sheets. To insure a secure bonding betweenthe core sheet and the surface plates the composite sheet is subjectedto pressure or to heat and pressure. The pressure is not sufcient to Imaterially reduce the insulation value of the core sheets. Along thelongitudinal edges of the sheet are formed kerfs I2, the object of whichwill be described later.

The pilasters may be formed in any desired manner but it is preferredthat they be of the type shown in Figure, 1 or 2. In Figure 1 thepilasters consist of two or more sheets of relatively thin metal, orsimilar material, having a fiat surface I3, and bent so as to formchannellike members i6. The channel-like members being iianked by adouble portion of the metal at I4, which is so arranged that certainamount of elasticity is provided. The free ends or tongue members i5 areso arranged that one extends in- 55 'member I6 is adapted to be insertedin the kerfs I2. 'Ihe Wedge like members preferably are a separate unitbut it may be formed in the channel member integral with the pilaster.

In assembling the metal clad panels and the l pilasters the edge to beinserted into a channel of the pilasters is forced together so as topartially close the kerf I2. The metal clad panel is inserted into thechannel and the edges spring back to the original position, thus.securely locking the panel in place. To insure a closer locking meansbetween the pilasters and the metal clad sheets wedge I6 may be insertedin kerfs I2. When the metal clad panels are inserted into the channelmembers of the pilasters the wedge members are forced into the kerf andexpand the insert part of the panels, thus securely locking them inplace.

,- In Figure 5 is shown another form of pilaster I9 and a modified formof wedge which entirely covers the edges of the core sheet. The coresheet I0 has the metal faces II secured thereto by any suitable meansand a kerf I2 extending along the edges of the core sheet. When the formof the wedge is used as shown in Figure 5 it is necessary that the faceplates II :project slightly beyond the edges of the core sheet I0. Thispermits the vface plate or extending wing portions of the Wedg 20 toabut evenly against the core sheet and gives an insulating materialwhich is wholly incased with metal.

When a wedge member, as disclosed in Figures 5 to 9, is utilized thesubstantially V shaped portion of the Wedge member is inserted into thekerf formed on the edges of the core sheet and when the core sheet isforced into the channel members of the pilasters the Wedge membersexpand the edges of the composite sheet, thus securely locking them inplace in the pilasters.

In Figures 7 and 8 is shown another modified form of wedges. 4If used itis unnecessary that the face plates I I project beyond the edge of thecore sheet. This is possible due to the fact that the Wedges 2| havetheir outer edges 22 nturned at an angle which is substantially parallelwith the V shaped portion of the Wedge. The wing portions of the wedges2| are forced into the core sheet by sufficient application of pressure,but such pressure not being sufficient to disrupt the bond between themetal face sheets and the core. The form of Wedge disclosed in Figure 8has the portions 22 tapered so as to provide a relatively sharp enteringmember, so as to facilitate the Wedges in entering the core sheet.

It is possible when the form of Wedges used as disclosed in Figures 7and 8 to Weld the Wedge members to the face plates and this may beaccomplished by any suitable means desired.my The 'term re proofmaterial as referred to herein is intended to include any suitablematerial that will answer the purpose intended and such a material thathas been found to be highly satisfactory is a specially treatedvermiculite.

When using a wedge of the type disclosed by Figures 5 to 9 it has oftenbeen found desirable to also use a wedge of the type disclosed in Figure4 in combination therewith to secure a better locking of the panel inthe pilasters.

What we claim is:

1. In combination with the composite struc- 5 tural material including acore of pulped vegetable material, having kerfs 'along theedges, metelsurface sheets secured'by a cementitious medium, and wedge-like membersadapted to be inserted in a plaster formed from at least two 10 sheetsof metal bent to form two channel members for the reception of thecomposite sheets and an opening between said channel members whereby apassage is provided for electrical conductors. l5

2. In a Wall structure including composite panel members having highheat insulating characteristics, kerfs extending along at least twoedges of said composite panels, pilasters provided with channels for thereception of the composite 20 panels and means for spreading the edgesof Athe kerfs to securely lock the composite panels in the pilasters.

3. In a Wall structure composite panels formed, from a core of pulpedvegetable material and 2 metal surface plates secured to the core, kerfslextending along the edges of vsaid composite panel, pilasters for thereception of the edges of said composite panel and means for locking thecomposite sheets and the pilaster into a unitary 3Q ,4 structure.

4. In combination with composite panels hav-l ing kerfs extending alongat least one edge of each panel, pilasters for receiving the edgesofsaid composite panels and means for entering the 35 kerfs and lockingthe edges of the composite panels and the pilasters together.

5. In combination with a composite structural panel, pilasters forreceiving the edges of said composite panel and means on said pilastersfor 4 0 1; spreading the edges of said composite panelv to securely locksaid panel and pilasters together. 6. In combination with compositepanels having kerfs extending along at least two edges thereof,pilasters for receiving the edges of said. 45;;

composite panels and means on said pilasters for locking the panels andthe pilasters together.

7. A composite structural unit formed from at core of pulpedligno-cellulose material, surface 56= plates of metal flanking the saidcore on opposite' sides, a casein cementing mediurnsecuring the core andthe slnface plates together, and kerfs extending along at least twoedges of said composite material. 55s

8. A fireproof; sound adsorptive,l composite, structural unit comprisinga core of pulped vegetable material treated with a fire-,proofingsolution, 'surface plates of metal flanking said core on opposite sides,a cementing medium securing-.68., the core and the surface platestogether, kerfs extending along the edges of said core sheet, and metalwedge members in said kerfs.

9. A iireproof, sound adsorptive, composite panel comprising a core ofpulped vegetable material treated with a iire resisting vermiculitematerial of a character that upon being subjected to high temperaturegenerates gas in quan? tities less than Will disrupt the panel, surfaceplates of metal adhesively secured to the core, 7&1. and kerfs extendingalong at least two edges of the said core.

10. In combination with pilasters provided with channels for thereception of edges of com-v posite panels, of panels consisting ofhomogene,

ous cores of puiped vegetable material, surface plates of metaladhesiveiy secured to said core, and kerfs extending along at least twoedges of said core.

11. A composite structural material formed from a. core of pulpedligno-cellulose material, surface plates of metal flanking the core onopposite sides, means for securing the surface plates to the core sheet,keri's extending along the edges of said core sheet and metal wedgemembers in t said kerfs, said wedges having wing portions cov-

